Form-in-place foam orthopedic splint system

Abstract

An apparatus and method for creating and using a lightweight custom-molded orthopedic appliance are disclosed. The orthopedic appliance is made up of an inner and an outer bladder containing components which, when combined by rupturing the inner bladder, react to form a rigid foam substance which may be conformed to the shape of the body part or surface in need of support, cushioning, or immobilization, and which quickly cures to form a firm, supportive brace for the affected body part.

What is claimed is:  
     
       1. A method of stabilizing a body part or surface comprising the steps of: 
       obtaining an orthopedic splint comprising:  
       an outer envelope having an inner face and an outer face, wherein the inner face has a textured surface, and wherein said outer envelope contains a polyol; and  
       an inner envelope containing isocyanate, wherein said inner envelope is adapted to be ruptured to allow the polyol and isocyanate to be mixed to form a polyurethane foam, and wherein said polyurethane foam hardens and adheres to said textured surface of said inner face within a curing time; and rupturing said inner envelope;  
       mixing said polyol and said isocyanate to initiate a chemical reaction that causes the formation of a polyurethane foam within said outer envelope;  
       positioning the orthopedic splint on the body part or surface to be stabilized;  
       molding said orthopedic splint around the contours of said body part or surface; and  
       allowing said polyurethane foam of said orthopedic splint to harden during said curing time.  
     
     
       2. The method of  claim 1 , wherein said inner envelope is fixed by at least one point to said outer envelope. 
     
     
       3. The method of  claim 1 , wherein the curing time is less than about 12 minutes. 
     
     
       4. The method of  claim 1 , wherein the curing time is less than about 10 minutes. 
     
     
       5. The method of  claim 1 , wherein the orthopedic splint is adapted to conform to the specific body part or surface to be stabilized. 
     
     
       6. The method of  claim 1 , wherein said polyurethane foam has a density of between about 8 and about 12 pounds per cubic foot. 
     
     
       7. The method of  claim 1 , wherein said polyurethane foam has a density of about 10 pounds per cubic foot.